Embossed carpet backing

ABSTRACT

Disclosed is a floor covering having an embossed polyurethane foam backing layer and methods of making and using same. A bottom surface of the backing layer can be thermo-embossed with a predetermined pattern, and the bottom surface of the backing layer can define at least one fluid pathway in communication with a side edge of the floor covering. The floor covering can also have a layer of skid-resistant material connected to the bottom surface of the backing layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 12/839,058, filed on Jul. 19, 2010, which claimsthe benefit of priority to U.S. Provisional Patent Application Ser. Nos.61/226,575, filed on Jul. 17, 2009, and 61/227,342, filed on Jul. 21,2009, the entire disclosures of which are incorporated by referenceherein for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to floor coverings having curedpolyurethane foam backing layers. More specifically, the curedpolyurethane foam backing layers can be thermo-embossed with apredetermined pattern. Also provided are methods for providing the floorcoverings and the cured embossed polyurethane foam backing layers.

BACKGROUND OF THE INVENTION

A backing material can be used with a carpet or textile to provide asupport, a cushion, a contamination barrier, a moisture barrier, or tosimplify installation of the carpet or textile. Backing or supportlayers often comprise a polyurethane foam. Typically, these polyurethanefoams are intermediately positioned within multi-layered backingmaterials and do not have any exposed external surfaces. Therefore,other textile materials are typically used in the outermost layer of thebacking material. However, these textile materials are often not anideal source for the outermost backing layer of floor coverings thatwill be exposed to certain external environments, including marineenvironments or other environments where the floor covering willencounter moisture. In addition, the outermost backing layers of floorcoverings cannot typically be embossed in a pattern that is fullyeffective to disperse moisture away from the floor covering. Further,floor coverings typically have a face layer and multiple backing layers,and this multi-layered configuration can increase the cost of the floorcovering.

Accordingly, there is a need to provide methods for producing floorcoverings and backing materials with embossed polyurethane foamcompositions that are embossed with predetermined patterns fordispersing fluids away from the floor coverings and backing materials.Additionally, there is a need to provide a cost-efficient floor coveringcomprising a greige good and a cured embossed polyurethane foam backingFurther, there is a need to provide a floor covering havingskid-resistant properties in marine environments. These needs and otherneeds are at least partially satisfied by the present invention.

SUMMARY

Disclosed are floor coverings and floor backings and methods of makingand using same. Generally, the floor covering has a greige good having aface surface and a back surface. In one aspect, a backing layer isprovided that can be made from cured embossed polyurethane foam. In thisaspect, the backing layer has a top surface that can connect to the backsurface of the greige good. In a further aspect, a bottom surface of thebacking layer can be thermo-embossed with a pre-determined pattern andcan define at least one fluid pathway in communication with a side edgeof the floor covering. In various aspects, it is contemplated that thepolyurethane foam is formed from a mechanically frothed, chemicallyblown, or mechanically frothed/chemically blown polyurethanecomposition.

Also disclosed are methods for making the floor coverings. Generally,the floor coverings can be made by providing a greige good and applyingthe foamable polyurethane composition to a selected surface of thegreige good. In one aspect, the applied polyurethane composition can bemetered to form a substantially uniform layer of the foamablepolyurethane composition having a predetermined thickness. Subsequently,the foamable polyurethane composition can be partially cured andembossed with a predetermined pattern. After embossing, the polyurethanecomposition can then be completely cured to provide a floor covering.

Additional embodiments of the invention will be set forth, in part, inthe detailed description, figures, and claims which follow, and in partwill be derived from the detailed description, or can be learned bypractice of the invention. It is to be understood that both theforegoing general description and the following detailed description areexemplary and explanatory only and are not restrictive of the inventionas disclosed.

DETAILED DESCRIPTION OF THE FIGURES

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 depicts a side perspective view of a portion of a floor coveringhaving an embossed carpet backing as described herein.

FIG. 2 depicts a cross-sectional view of a portion of the floor coveringof FIG. 1.

FIGS. 3A and 3B are schematic drawings of an exemplary belted oven andprocessing apparatus for manufacturing the floor covering of FIG. 1.

FIG. 4 is a schematic drawing of an exemplary tenter apparatus and ovenfor manufacturing the floor covering of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this invention is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,as such can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. Accordingly, those who work in the art will recognize thatmany modifications and adaptations to the present invention are possibleand can even be desirable in certain circumstances and are a part of thepresent invention. Thus, the following description is provided asillustrative of the principles of the present invention and not inlimitation thereof.

As used herein, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Thus, forexample, reference to a “surface” includes aspects having two or moresuch surfaces unless the context clearly indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition or article,denotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a composition or a selectedportion of a composition containing 2 parts by weight of component X and5 parts by weight component Y, X and Y are present at a weight ratio of2:5, and are present in such ratio regardless of whether additionalcomponents are contained in the composition.

A weight percent of a component, unless specifically stated to thecontrary, is based on the total weight of the formulation or compositionin which the component is included.

As used herein, and unless the context clearly indicates otherwise, theterm “carpet” is used to generically include broadloom carpet, carpettiles, and even area rugs. To that end, “broadloom carpet” means abroadloom textile flooring product manufactured for and intended to beused in roll form. “Carpet tile” denotes a modular floor covering,conventionally in 18″×18,” 24″×24″ or 36″×36″ squares, but other sizesand shapes are also within the scope of the present invention.

The present invention may be understood more readily by reference to thefollowing detailed description of preferred embodiments of the inventionand the examples included therein and to the Figures and their previousand following description.

In a first aspect, and referring to FIG. 1 and FIG. 2, the presentdisclosure provides generally a floor covering 10 having a plurality ofside edges 15 and comprising a greige good 20 and a backing layer 30. Inone aspect, the greige good 20 has a face surface 22 and an opposed backsurface 24. In another aspect, the backing layer 30 has a top surface 32and an opposed bottom surface 34 and can be sized and shaped foroperably coupling the top surface 32 of the backing layer 30 to the backsurface 24 of the greige good 20. In a further aspect, at least aportion of the bottom surface 34 of the backing layer 30 can bethermo-embossed with a pre-determined pattern 40. In still a furtheraspect, the embossed portion of the bottom surface 34 of the backinglayer 30 can define at least one fluid pathway 42 in communication withat least one side edge 15 of the floor covering 10. In one example, itis contemplated that the backing layer 30 can comprise cured embossedpolyurethane foam.

In one aspect, the greige good 20 can comprise a plurality of facefibers and a primary backing. The face fibers of the greige good 20 cancomprise, for example and without limitation, polypropylene,polyethylene terephthalate (PET), nylon 6, and nylon 6,6, and/or liketextile face fibers. The primary backing of the greige good 20 cancomprise any substrate material, including, for example and withoutlimitation, woven textile fabrics, non-woven textile fabrics, or acombination of woven and non-woven textile fabrics.

In exemplary embodiments, the primary backing can be a woven ornon-woven polymeric scrim material. Exemplary woven polymeric scrims caninclude woven polypropylene primary backing materials. When the primarybacking is a woven textile fabric, such as the exemplary wovenpolypropylene primary backing, the textile can be formed as flat weavecomprised of tape yarns, spun yarns, or a combination of both tape andspun yarns. Still further, suitable woven polypropylene materials canhave from 24 to 32 warp threads (threads in the longitudinal direction)per inch and from 10 to 22 weft threads (threads drawn over and underthe warp threads to form the fabric weave) per inch. In an exemplarypreferred embodiment, the woven polymeric fabric comprises 28 warpthreads and 10 weft threads per square inch of fabric. In an alternativepreferred embodiment, the woven polymeric fabric comprises 28 warpthreads and 12 weft threads per square inch of fabric. An example of acommercially available polypropylene material is a (28×10) wovenpolypropylene flat weave S7704 as supplied by Sythetic Industries (12454N Highway 27, Chickamauga, Ga., 30707, U.S.A.).

As noted, in one aspect it is contemplated that the primary backing ofthe greige good 20 can also comprise a non-woven textile material.Exemplary non-woven textile materials include spun-bonded textiles,hydro-entangled textiles, thermally bonded textiles, wet-laid,melt-blown, air entangled, and needle-punched textiles. In still otherembodiments, the primary backing can be a combination of woven andnon-woven textile materials. For example, in an embodiment the primarybacking can be a fleeced woven primary backing material, whereby apolymeric woven textile is needle-punched with staple fibers to providea fleeced woven backing material such as a fleeced backing materialmanufactured by Propex Fabrics, Style 4005 (24×10 FLW) (Dalton, Ga.U.S.A.).

The greige good 20 can comprise virgin, recycled, waste material, or acombination thereof. For example, in a preferred embodiment, the greigegood can comprise one or more polymeric materials reclaimed from priormanufactured carpet or other floor covering components. The priormanufactured carpet or other floor covering can include post consumer,post commercial, post residential, post industrial, manufacturingremnants, quality control failures, and the like. Such reclaimedmaterial can be present in the greige good 20 in percentages rangingfrom 0 up to 100%. For example, the greige good can comprise 10%, 20%,50%, 40%, 60%, 80%, or 100% post residential or post consumer carpetproducts. In one exemplary embodiment, the primary backing of the greigegood 20 comprises at least about 30% or optionally at least about 50%reclaimed material, such as post consumer carpet material, postindustrial carpet material, post commercial carpet material, or acombination thereof.

As one skilled in the art will appreciate, the cured embossedpolyurethane foam of the backing layer 30 can be manufactured accordingto any conventionally known process and formulation for manufacturingpolyurethane foam. For example, and without limitation, the curedembossed polyurethane foam can generally be prepared by admixing a firstcomponent, such as a polyisocyanate, with a second component, such as anactive hydrogen containing material, wherein a gas is introduced thereinor produced in situ to form bubbles which in turn form a reduced densityexpanded cell-like structure in the cured polyurethane. The process ofintroducing the bubbles is known as mechanically blowing or frothing theformulation. The process of forming bubbles in situ is commonly referredas chemically blowing. The greater the amount of gas introduced into apolyurethane formulation, the lower the density of the resultant foamproduced therewith. However, with polyurethane foams generally and withpolyurethane foams used in floor covering applications in particular,reducing foam density can also decrease or reduce other properties ofthe polyurethane foam which can make it a desirable material for use infloor covering applications.

In a preferred embodiment, the cured embossed polyurethane foam of thebacking layer 30 is formed from a polyurethane composition that has beenboth mechanically frothed and chemically blown, such as those disclosedand described in U.S. Pat. No. 6,372,810, the entire disclosure of whichis incorporated by reference herein. Polyurethane foams of this naturecan be prepared from formulations comprising a polyisocynate componentin combination with relatively high levels of a catalyst, a surfactant,and water.

The high level of water can cause a chemical blowing of the foamcomposition when the water reacts with the polyisocyanate component ofthe polyurethane formulation. The combination of the mechanical frothingand chemical blowing from the reaction of a polyisocyanate and waterresults in polyurethane foam having lower densities than thoseconventionally used in floor covering applications, such as carpetbackings and carpet underlays. It should also be appreciated that thepolyurethane foams so produced can have sufficiently low densities to beless expensive than conventional polyurethane foams for carpetapplications, while maintaining sufficient resiliency and dimensionalstability to be desirable for use in various floor coveringapplications. Such a low density can be achieved for example, byminimizing off-gassing from the polyurethane composition during thecuring process, thus providing a cured foam having an expanded cellstructure.

In one aspect, the cured embossed polyurethane foam can be thermo-set.As one will appreciate, by thermo-setting the polyurethane foam, thecured embossed polyurethane foam can be irreversibly cured. As one willfurther appreciate, the irreversibly cured polyurethane foam canincrease the strength of the backing material 30 of the floor covering10.

In another aspect, the synergistic combination of mechanical blowing andchemical blowing can be made possible by the inclusion of high levels ofcatalyst, water, and surfactant in the formulations used to prepare thepolyurethane foam. The foam formulations used to prepare the curedembossed polyurethane foam can have from about 0.5 to about 3 partswater per hundred parts polyol, preferably from about 0.75 to about 2.75parts water per hundred parts polyol, and more preferably from about 1.5to about 2.5 parts water per hundred parts polyol. The formulations ofthe cured embossed polyurethane foam can also include from about 0.01 toabout 3.5 parts urethane catalyst per hundred parts polyol, and from 1to 2 parts surfactant per hundred parts polyol.

The cured embossed polyurethane foam can have any desired density, whichwill depend on the desired use of the foam. In one aspect, the foam canhave a density of from about 2 to about 60 pounds per cubic foot,preferably from about 3 to about 30, more preferably from about 6 toabout 18, and even more preferably from about 6 to about 14 pounds percubic foot. For use in a residential floor covering, an exemplaryembossed polyurethane foam can have a density from about 1 to about 10pounds per cubic foot, including, for example, 2, 4, 6, or 8 pounds percubic foot. For use in a commercial floor covering, an exemplaryembossed polyurethane foam can have a density from about 11 to about 20pounds per cubic foot, including, for example, 12, 14, 16, or 18 poundsper cubic foot. Alternatively, for use as a laminate flooringunderlayment, an exemplary embossed polyurethane foam can have a densityfrom about 15 to about 25 pounds per cubic foot, including, for example,16, 18, 20, 22, and 24 pounds per cubic foot.

The cured embossed polyurethane foam can also have any desiredthickness, which will generally depend on the composition of the greigegood, as well as the amount and composition of polyurethane depositedprior to curing. Exemplary embodiments have thickness of from about 80mils to about 500 mils, including, without limitation, embodimentshaving thicknesses of about 90 mils, 100 mils, 120 mils, 140 mils, 160mils, 180 mils, 200 mils, 240 mils, 250 mils, 280 mils, 320 mils, 350mils, 400 mils, and 450 mils. In a specific exemplary embodiment, thecured embossed polyurethane foam can have a desired thickness of betweenabout 1/16 and ½ inch, more preferably between about ⅛ and ⅜ inch, andmost preferably between about 3/16 and ¼ inch.

Exemplary formulations suitable to provide the foam include thoseformulations disclosed and described in U.S. Pat. No. 5,104,693 (theentire disclosure of which is incorporated by reference herein) butadditionally including from about 0.5 to about 3 parts water per hundredparts of polyol, from about 0.01 to about 3.5 parts urethane catalystper hundred parts of polyol, and from 1 to 2 part surfactant per hundredparts of polyol. In formulations of this type, the polyol component canbe at least one isocyanate reactive material having an averageequivalent weight of about 1,000 to about 5,000 daltons.

The polyisocyanate can be any polyisocyanate sufficient to provide anisocyanate index of about 90 to about 130, wherein at least 30 percentby weight of the polyisocyanate is a soft segment prepolymer which isthe reaction product of a stoichiometric excess of MDI or an MDIderivative and an isocyanate reactive organic polymer having anequivalent weight from about 500 to about 5,000, the prepolymer havingan isocyanate group content of about 10 to about 30 percent by weight.The underlay can be prepared by frothing the reactants with air withfurther blowing as the water reacts with isocyanate to produce carbondioxide.

The polyurethane foam can comprise a polyol component. The polyolcomponent of the foam formulation can be any polyol or polyol mixturewhich can be used to prepare a foam which can withstand the physicalproperty and handling requirements of foams used in carpet or textileapplications. For example, the polyol component can be a polyol mixturehaving as one part of the mixture a polyol based on a C3-C8 alkyleneoxide, which has an equivalent weight of about 1000 to about 5000daltons, and an internal poly(ethylene oxide) block or a terminalethylene oxide cap constituting about 15 to about 30 percent of theweight of the polyol, or mixture of such polyols wherein the polyol ormixture thereof has an average functionality of about 1.8 to about 2.5,preferably from about 1.8 to about 2.4 and more preferably from about a1.8 to about 2.3. The other portion of the polyol mixture is preferablya minor amount of a low equivalent weight compound having about 2 activehydrogen containing groups per molecule.

The polyurethane foam can be prepared with conventional polyurethanecatalysts including, but not limited to, tertiary amine catalysts suchas triethylenediamine, N-methyl morpholine, N-ethyl morpholine, diethylethanolamine, N-coco morpholine, 1-methyl-4-dimethylaminoethylpiperazine, 3-methoxy-N-dimethylpropylamine, N,N-diethyl-3-diethylaminopropylamine, dimethylbenzyl amine and the like; organotin catalystssuch as dimethyltin dilaurate, dibutyltin dilaurate, dioctyltindilaurate, stannous octoate and the like; and isocyanurate catalystssuch aliphatic and aromatic tertiary amine compounds, organotincompounds, alkali metal salts of carboxylic acids, phenols, symmetricaltriazine derivatives, and the like.

If an organotin catalyst is used, a suitable cure can be obtained usingfrom about 0.01 to about 0.5 parts per 100 parts of the polyol, byweight. By “suitable cure,” it is meant that a relatively rapid cure toa tack-free state is obtained. If a tertiary amine catalyst is used, thecatalyst preferably provides a suitable cure using from about 0.01 toabout 3 parts of tertiary amine catalyst per 100 parts of the polyol, byweight. Both an amine type catalyst and an organotin catalyst can beemployed simultaneously in any combination or ratio. If a combination ofamine catalyst and organotin catalyst is used, the catalysts can be usedin an amount of from about 0.02 to about 3.5 parts per 100 parts ofpolyol, by weight.

The polyurethane foam can be prepared using both mechanical and chemicalblowing agents. The mechanical blowing agent is introduced into a foamforming mixture by a mechanical device. The blowing agent is preferablyair, however, other gasses, such as carbon dioxide, nitrogen, and thelike can be used. The blowing agent is preferably introduced into thepolymer by frothing. A frother is a mechanical device which injects theblowing agent into an admixture as it agitates the admixture. Chemicalblowing agents as used herein are volatile materials, or materials thatproduce gaseous materials as the result of a chemical reaction. Chemicalblowing agents useful for these purposes include, for example, liquidssuch as water, volatile halogenated alkanes such as the variouschlorfluoromethanes and chlorfluoroethanes; azo-blowing agents such asazobis(formamide). Water is the preferred chemical blowing agent.

The polyurethane foam can be prepared from formulations that can alsoinclude fillers. The fillers can be any suitable filler, including, forexample, aluminum oxide trihydrate (alumina), calcium carbonate, bariumsulfate or mixtures thereof. As one skilled in the art will appreciate,it is contemplated that other fillers can also be used, such as, forexample and without limitation, virgin materials, waste materials,reclaimed materials; recycled materials, pre and post consumer andindustrial materials, pre and post consumer and industrial carpetmaterials, carpet materials in any form, and the like. On non-limitingexample of recycled fillers include coal fly ash, which has been foundto be useful in amounts from about 100 to about 400 parts by weight.

In general, the formulations used to prepare the polyurethane foaminclude fillers at any desired level. For example, the amount of fillercan be determined relative to parts polyol. To that end, an exemplarypolyurethane foam can have from about 80 parts per hundred parts ofpolyol to about 250 parts per hundred parts of polyol, including,without limitation, 90, 100, 120, 130, 150, 160, 190, 200, 220, and 140parts per hundred parts of polyol. Alternatively, the amount of fillercan be determined relative to any other desired component of thepolyurethane composition, or even relative to the total weight of thepolyurethane composition. For example, in an exemplary and non-limitingembodiment, the polyurethane foam can comprise from about 100 to about200 parts by weight filler, including, for example, 110, 120, 130, 140,150, 160, 170, 180, and 190 parts by weight filler, relative to thetotal weight of the polyurethane.

In one aspect, the polyisocyanate component of the formulations used toprepare the polyurethane foam can be conveniently selected from organicpolyisocyanates, modified polyisocyanates, isocyanate-based prepolymers,and mixtures thereof. These can include aliphatic and cycloaliphaticisocyanates, aromatic and multifunctional aromatic isocyanates.Exemplary polyisocyanates include, but are not limited to, 2,4- and2,6-toluenediisocyanate and the corresponding isomeric mixtures; 4,4′-,2,4′- and 2,2′-diphenyl-methanediisocyanate and the correspondingisomeric mixtures; mixtures of 4,4′-, 2,4′- and2,2′-diphenylmethanediisocyanates and polyphenyl polymethylenepolyisocyanates PMDI; and mixtures of PMDI and toluene diisocyanates.Aliphatic and cycloaliphatic isocyanate compounds are also useful forpreparing the polyurethanes. Such examples, include1,6-hexamethylene-diisocyanate;1-isocyanato-3,5,5-trimethyl-1-3-isocyanatomethyl-cyclohexane; 2,4- and2,6-hexahydrotoluenediisocyanate, as well as the corresponding isomericmixtures; 4,4′-, 2,2′- and 2,4′-dicyclohexylmethanediisocyanate, as wellas the corresponding isomeric mixtures.

Modified multifunctional isocyanates can also be used, i.e., productswhich are obtained through chemical reactions of the above diisocyanatesand/or polyisocyanates. Examples include polyisocyanates containingesters, ureas, biurets, allophanates and including carbodiimides and/oruretonimines; isocyanurate and/or urethanes containing diisocyanates orpolyisocyanates. Liquid polyisocyanates containing carbodiimide groups,uretonimine groups and/or isocyanurate rings, having isocyanate groups(NCO) contents (42/polyisocyanate mwt) of from about 10 to about 40weight percent, or from about 20 to about 35 weight percent, can also beused. These include, for example, polyisocyanates based on 4,4′-, 2,4′-and/or 2,2′-diphenylmethane diisocyanate and the corresponding isomericmixtures, 2,4- and/or 2,6-toluenediisocyanate and the correspondingisomeric mixtures; mixtures of diphenylmethane diisocyanates and PMDIand mixtures of toluenediisocyanates and PMDI and/or diphenylmethanediisocyanates.

Prepolymers can also be useful with the formulations used to prepare thepolyurethane foam. In one aspect, suitable prepolymers are prepolymershaving NCO contents of from about 5 to about 40 weight percent, morepreferably from about 15 to about 30 weight percent. These prepolymersare prepared by reaction of the di- and/or polyisocyanates withmaterials such as lower molecular weight diols and triols, but also theycan be prepared with multivalent active hydrogen compounds such as di-and tri-amines and di- and tri-thiols. Specific examples includearomatic polyisocyanates containing urethane groups, having NCO contentsof from about 5 to about 40 weight percent, or about 20 to about 35weight percent, obtained by reaction of diisocyanates and/orpolyisocyanates with, for example, lower molecular weight diols, triols,oxyalkylene glycols, dioxyalkylene glycols or polyoxyalkylene glycolshaving molecular weights up to about 800. These polyols can be employedindividually or in mixtures as di- and/or polyoxyalkylene glycols. Forexample, diethylene glycols, dipropylene glycols, polyoxyethyleneglycols, polyoxypropylene glycols and polyoxypropylenepolyoxyethyleneglycols can be used.

Polyisocyanates having an NCO content of from 8 to 40 weight percentcontaining carbodiimide groups and/or urethane groups, from4,4′-diphenylmethane diisocyanate or a mixture of 4,4′- and2,4′-diphenylmethane diisocyanates can also be used with theformulations. Additionally, prepolymers containing NCO groups, having anNCO content of from about 20 to about 35 weight percent, based on theweight of the prepolymer, prepared by the reaction of polyoxyalkylenepolyols, having a functionality of from 2 to 4 and a molecular weight offrom about 800 to about 15,000 with 4,4′-diphenylmethane diisocyanate orwith a mixture of 4,4′- and 2,4′-diphenylmethane diisocyanates andmixtures of polyisocyanates and prepolymers; and 2,4- and2,6-toluene-diisocyanate or the corresponding isomeric mixtures. PMDI inany of its forms can also be used. PMDI can have an equivalent weight offrom about 125 to about 300, or from about 130 to about 175, with anaverage functionality of greater than about 2. An average functionalitycan also be from about 2.5 to about 3.5. The viscosity of thepolyisocyanate component can be from about 25 to about 5,000 centipoise(cps) (0.025 to about 5 PaYs), but values from about 100 to about 1,000cps at 25 .degree. C. (0.1 to 1 PaYs) are also useful for ease ofprocessing. Similar viscosities are useful where alternativepolyisocyanate components are selected. In one aspect, thepolyisocyanate component of the formulations of the present invention isselected from MDI, PMDI, an MDI prepolymer, a PMDI prepolymer, amodified MDI, and a combination thereof.

Polyfunctional active hydrogen containing materials useful with thepresent formulations can include materials other than those describedabove. Active hydrogen containing compounds commonly used inpolyurethane production are those compounds having at least two hydroxylgroups. Those compounds are referred to herein as polyols.Representatives of suitable polyols are generally known and aredescribed in such publications as High Polymers, Vol. XVI,“Polyurethanes, Chemistry and Technology” by Saunders and Frisch,Interscience Publishers, New York, Vol. I, pp. 32-42, 44-54 (1962) andVol. II, pp. 5-6, 198-199 (1964); Organic Polymer Chemistry by K. J.Saunders, Chapman and Hall, London, pp. 323-325 (1973); and Developmentsin Polyurethanes, Vol. I, J. M. Burst, ed., Applied Science Publishers,pp. 1-76 (1978). However, any active hydrogen containing compound can beused with the present invention. Examples of such materials includethose selected from the following classes of compositions, alone or inadmixture: (a) alkylene oxide adducts of polyhydroxyalkanes; (b)alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c)alkylene oxide adducts of phosphorus and polyphosphorus acids; and (d)alkylene oxide adducts of polyphenols. Polyols of these types arereferred to herein as “base polyols”. Examples of alkylene oxide adductsof polyhydroxyalkanes useful herein are adducts of ethylene glycol,propylene glycol, 1,3-dihydroxypropane, 1,4-dihydroxybutane, and1,6-dihydroxyhexane, glycerol, 1,2,4-trihydroxybutane,1,2,6-trihydroxyhexane, 1,1,1-trimethylolethane,1,1,1-trimethylolpropane, pentaerythritol, polycaprolactone, xylitol,arabitol, sorbitol, mannitol, and the like. Examples of alkylene oxideadducts of polyhydroxyalkanes are the ethylene oxide adducts oftrihydroxyalkanes. Other useful adducts include ethylene diamine,glycerin, ammonia, 1,2,3,4-tetrahydroxy butane, fructose, and sucrose.

Also useful are poly(oxypropylene) glycols, triols, tetrols and hexolsand any of these that are capped with ethylene oxide.Poly(oxypropyleneoxyethylene)polyols is an exemplary, non-limitingpolyols. The oxyethylene content conveniently comprise less than about80 weight percent of the total polyol weight, or less than about 40weight percent. The ethylene oxide, if used, can be incorporated in anyway along the polymer chain, for example, as internal blocks, terminalblocks, or randomly distributed blocks, or any combination thereof.

Polyamines, amine-terminated polyols, polymercaptans and otherisocyanate-reactive compounds are also suitable for use with thedisclosed formulations. Polyisocyanate polyaddition active hydrogencontaining compounds (PIPA) are particularly preferred for use with thepresent invention. PIPA compounds are typically the reaction products ofTDI and triethanolamine. A method for preparing PIPA compounds can befound in, for example, U.S. Pat. No. 4,374,209, issued to Rowlands.

Another preferred class of polyols are “copolymer polyols”, which arebase polyols containing stably dispersed polymers such asacrylonitrile-styrene copolymers. Production of these copolymer polyolscan be from reaction mixtures comprising a variety of other materials,including, for example, catalysts such as azobisisobutyro-nitrile;copolymer polyol stabilizers; and chain transfer agents such asisopropanol. Polyols comprising natural oils such as soy, sunflower, andsafflower oil can be desirable in combination with standard petroleumbased polyols. It should be appreciated that such oils can help tooffset the overall carbon footprint of the product.

In an exemplary embodiment, the polyurethane foam can comprise about 160parts of a blend of isocyanate and a selected polyol and approximately100 parts of a filler containing calcium carbonate. As one willappreciate, the calcium carbonate can enhance curing of the polyurethanefoam. It is contemplated that the density of the polyurethane foam ofthis embodiment can be between about 400 to 500 grams per quartmeasured.

In one aspect, and referring to FIG. 1 and FIG. 2, the bottom surface 34of the backing layer 30 of the floor covering 10 can define at least onemale projection 44. In this aspect, at least one fluid pathway 42 of thebottom surface 34 can be defined therebetween adjacent respective maleprojections 44 of the at least one male projection. In one aspect, eachmale projection 44 of the at least one male projection can have a distalend 45. In another aspect, the at least one male projection 44 cancomprise a plurality of raised bands. In one exemplary embodiment, asshown in FIG. 1, the at least one male projection 44 can comprise aplurality of raised serpentine bands. In another embodiment, the atleast one male projection 44 can comprise a plurality of raisedstraight-ribbed bands. In an additional embodiment, the at least onemale projection 44 can comprise a plurality of raised bands having a dogbone crosshatch configuration. As one of ordinary skill in the art willappreciate, the at least one male projection 44 can comprise a pluralityof raised bands having any raised relief shape or configuration. Inanother aspect, the at least one male projection 44 can comprise aplurality of substantially parallel raised bands. In a further aspect,the at least one male projection 44 can be outwardly sloped from thedistal ends 45 of the at least one male projection toward the backinglayer 30.

As one will appreciate, the at least one male projection 44 can beconfigured to promote the flow of moisture to the at least one fluidpathway 42. As one will further appreciate, the at least one fluidpathway 42 defined therebetween the male projections 44 of the backinglayer 30 can be configured to disperse moisture and air through the atleast one fluid pathway to at least one side edge 15 of the floorcovering 10.

In an additional aspect, the distal ends 45 of the at least one maleprojection 44 correspond to a portion of the cross-sectional area of thebottom surface 34 of the backing layer 30. For example, and withoutlimitation, the cross-sectional area of the distal ends 45 of the atleast one male projection 44 can be at least 10%, 20%, 30%, 40%, 50%,60%, 70%, 80%, or 90% of the cross-sectional area of the bottom surface34 of the backing layer 30. In a further aspect, the predeterminedpattern 40 that is embossed therein the polyurethane composition canhave a selected depth. In exemplary embodiments, the selected depth ofthe predetermined embossed pattern 40 can be between about 1/32 inch and½ inch, more preferably between about 1/16 inch and ¼ inch, and mostpreferably between about ⅛ inch and 3/16 inch.

In another aspect, and referring to FIG. 2, the backing layer 30 of thefloor covering 10 can further comprise a layer of cured skid-resistantmaterial 50 connected to at least a portion of the bottom surface 34 ofthe backing layer. For example, the skid-resistant material 50 can beapplied on the distal most portions of the at least one male projection44. In one aspect, the skid-resistant material 50 can be configured tobe slip-resistant to a selected material, for example and withoutlimitation, fiberglass. As one will appreciate, the skid-resistantmaterial 50 can provide additional stability to the floor covering 10when used in wet or moist environments, including, for example andwithout limitation, marine environments.

In another aspect, and as one will appreciate, due to the specificgravity of the greige good 20 and the presence of closed cells inportions of the backing layer 30, the floor covering 10 can beconfigured to float in water. It is contemplated that the floor covering10 can function as a floating device as needed.

In another aspect, the skid-resistant material 50 can comprise apolymer. In an additional aspect, the skid-resistant material 50 cancomprise an acrylic polymer. In a further aspect and as exemplarilyshown in FIG. 2, the skid-resistant material 50 can comprise an acrylicpolymer blended with water. In an exemplary embodiment, theskid-resistant material 50 can comprise an acrylic polymer blended withwater such that between about 50% and 60% of the skid-resistant materialcomprises solid material. In a specific exemplary embodiment, theskid-resistant material 50 can comprise an acrylic polymer blended withwater such that about 52% of the skid-resistant material comprises solidmaterial. In another aspect, the skid-resistant material 50 can compriselatex. In a further aspect, the weight of the skid-resistant material 50can be about two ounces per square yard of floor covering.

In an additional aspect, the backing layer 30 can have a selected depthof between about 1/16 and ½ inch, more preferably between about ⅛ and ⅜inch, and most preferably between about 3/16 and ¼ inch. For example,the selected depth of the backing layer 30 can be, without limitation, a0.1, 0.2, 0.3, and 0.4 inch depth, although virtually any depth can beused. In a further aspect, the backing layer 30 can have a weight offrom about 10 to about 50 ounces per square yard of material, morepreferably from about 20 to about 40 ounces per square yard. In oneexemplary embodiment, the weight of the backing layer 30 can be about 24ounces per square yard. In still a further aspect, the backing layer 30can have a density of from about 8 to about 22 pounds per cubic foot,more preferably from about 10 to about 15 pounds per cubic foot, andmost preferably from about 12 to about 14 pounds per cubic foot.

The present invention also provides a method for producing the floorcovering 10 disclosed and described herein. In a first aspect, andreferring to FIGS. 3A AND 3B, the method for producing the floorcovering comprises providing the greige good 20 as described herein. Inanother aspect, the method comprises applying a foamable polyurethanecomposition 36 as described herein to the back surface 24 of the greigegood 20. In another aspect, the method comprises metering the appliedpolyurethane composition 36 to form a substantially uniform layer of thefoamable polyurethane composition having a predetermined thickness. Inan additional aspect, the method comprises partially curing the foamablepolyurethane composition 36. In a further aspect, the method comprisesembossing the partially cured polyurethane composition with thepredetermined pattern 40. In still a further aspect, the methodcomprises curing the embossed polyurethane composition.

In another aspect, the method can further comprise applying the layer ofskid-resistant material 50 to at least a portion of a top surface of thecured embossed polyurethane composition. In an additional aspect, theapplication of the layer of skid-resistant material 50 can compriseapplying the skid-resistant material to at least a portion of the topsurface of the cured embossed polyurethane composition using a rollapplicator 60. For example, and without limitation, the skid-resistantmaterial 50 can be applied to at least a portion of the top surface ofthe cured embossed polyurethane composition using a lick roller. In afurther aspect, the method can further comprise curing the layer ofskid-resistant material 50.

In an additional aspect, following the production of the floor covering10, the floor covering can be transported through additionalpost-manufacture processing steps. For example, and without limitation,the floor covering can be transported through a roll-up process 70.However, it is contemplated that the floor covering 10 can betransported through any other post-manufacturing process known in theart.

The polyurethane foam, as discussed above, can be an uncuredmechanically frothed and chemically blown polyurethane composition. Insome embodiments, it can be preferable to premix all of the componentsof the foam formulation except polyisocyanate (and the blowing agentwhen a gas is used). The polyisocyanate and other components, asdiscussed above, can first be admixed and then the blowing agent gas canbe blended in using, for example, a mixer, such as an OAKES FROTHER.Variable speed pumps can be used to transport the separate components tothe mixer. The composition can then be applied to the back surface 24 ofthe greige good 20 prior to curing. In an exemplary embodiment, thepolyurethane composition can be applied to the back surface 24 of thegreige good 20 within about 10 to 30 seconds of mixing of the separatecomponents.

In one aspect, and referring to FIG. 1, FIG. 3A, and FIG. 3B, the greigegood 20 can be provided from a roll 120. In another aspect, the foamablepolyurethane composition 36 can be applied to the back surface 24 of thegreige good 20 using a foam applicator 80. In an additional aspect, theapplied polyurethane composition can be metered to a desired thicknessusing a blade 90, such as, without limitation, an air blade, a knifeblade, an extruder blade, a doctor blade, and the like. In an exemplaryaspect, the applied polyurethane composition can be metered within about1 to 3 seconds of application of the foamable polyurethane composition36 to the back surface 24 of the greige good 20. In a further aspect,following the partial curing of the foamable polyurethane composition36, the partially cured polyurethane composition can be embossed with apredetermined pattern 40 by passing the greige good/partially curedbacking material therebetween an embossing roller 100 and a press roller102. The embossing roller 100 and the press roller 102 cooperateconventionally to ensure that the surface of the embossing roller ispressed thereinto the surface of the partially cured polyurethanecomposition so as to form the desired embossed pattern. In still afurther aspect, the embossing roller 100 can be coated with water priorto embossing the partially cured polyurethane composition.

In another aspect, the steps of partially curing the foamablepolyurethane composition 36 and curing the embossed polyurethanecomposition are performed in an oven 110. In an additional aspect,following the application of the skid-resistant material 50 to the curedembossed polyurethane composition, the step of curing the layer ofskid-resistant material can be performed in the oven 110.

In an exemplary embodiment, the oven 110 can be a belted oven.Alternatively, with reference to FIG. 1 and FIG. 4, the greige good 20can be provided from the roll 120 using a tenter apparatus (not shown).As will be apparent, the present composite structures are uniquelycompatible with tenter-based machinery. It should be appreciated thatthe use of a tenting apparatus can provide advantages over using othermanufacturing equipment, including belt-driven machinery. For example, atenting apparatus does not require the use of a belt, which can becostly to maintain and replace, since the offline machinery time alonecan present substantial economic loss.

In addition, the versatility of composite structures that can beproduced by a belt-driven process is limited. With a double belt-drivenprocess, the belts themselves provide a gas impermeable barrier to thefoam layer. The belt coatings provide a substantially constant gasimpermeability, such that resulting foam composites have similardensities. To replace such coatings in order to provide composites withvarying densities can be costly. In accordance with the present methods,however, the backing layer 30 and a protection layer 135, as opposed toa belt, can provide gas impermeable layers when used with a tentingapparatus. It is contemplated that the protective layer 135 cancomprise, for example and without limitation, woven, non-woven, spunbound fabrics, films, textiles and the like. As illustrated in FIG. 4,it is contemplated that the protective layer can be provided by a filmlayering apparatus 130, which can comprise, for example and withoutlimitation, one or more rollers. As discussed herein, the backing layer30 and the protective layer 135 can comprise a variety of differentmaterials, all with varying levels of gas permeability. Thus, compositestructures with varying density levels can be provided by simplychanging the properties of the backing layer and the protective layer,without substantially altering manufacturing conditions.

Furthermore, the present methods provide improved heat transfer from thecuring oven to the foam layer by using a tenter apparatus in combinationwith a three-layer structure. Heat transfer is limited in a belt-drivenprocess by the heat transfer capacity of the belts themselves, whereasaccording to the present methods, differing degrees of heat transfer canbe accomplished by simply utilizing different materials as the backinglayer and/or the film layer, as discussed above. The use of a tenterapparatus to produce floor coverings as described herein is furtherdescribed in U.S. patent application Ser. No. 12/619,059, the entiredisclosure of which is incorporated by reference herein.

Regardless of whether a tenter apparatus or a belted oven is used in themethods described herein, it is contemplated that the curing steps canbe carried out in any suitable oven, including, without limitation, asingle pass oven, a multiple pass (including a double or triple passoven), an infrared oven, an open-flamed oven, and an open-flamed forceddraft convection impingement oven, or simply with a heating plate, theselection of which can depend, in one aspect, on available space at amanufacturing facility. It is contemplated that the method of productiondescribed herein can be completed by passing the floor covering 10through one or more ovens for one, two, three or more passes asnecessary and desired.

In an exemplary embodiment, as shown in FIGS. 3A AND 3B, the curingsteps can be carried out in a triple pass oven, for example, and withoutlimitation, a 110 foot triple pass oven. In a first aspect, andreferring to FIG. 2 and, FIG. 3A, and FIG. 3B, the step of partiallycuring the foamable polyurethane composition 36 can be performed in afirst pass through the triple pass oven 110. During this first passthrough the oven 110, the floor covering 10 can be positioned with theface surface 22 facing downwardly. As one will appreciate, positioningthe floor covering 10 with the face surface 22 facing downwardly duringthe first pass through the oven 110 permits effective curing of thefoamable polyurethane composition 36. It is contemplated that the floorcovering 10 can begin the first pass through the oven 110 atapproximately 30 to 45 seconds after application of the foamablepolyurethane composition 36 to the greige good 20.

In another aspect, the step of curing the embossed polyurethanecomposition is performed in a second pass through the triple pass oven110. During this second pass through the oven 110, the floor covering 10can be positioned with the face surface 22 facing upwardly. As one willappreciate, positioning the floor covering 10 with the face surface 22facing upwardly during the second pass through the oven 110 helpspreserve the structure of the partially cured polyurethane compositionafter it is embossed with the predetermined pattern 40.

In a further aspect, and referring to FIG. 2, FIG. 3A, and FIG. 3B,after the second pass through the oven 110, the layer of skid-resistantmaterial 50 can be applied to at least a portion of the top surface ofthe cured embossed polyurethane composition. In an exemplary method, thelayer of skid-resistant material 50 can be applied to at least a portionof the distal ends 45 of the at least one male projection 44. In oneaspect, and as shown in FIGS. 3A AND 3B, the skid-resistant material 50can be applied by a roll applicator 60 positioned underneath the floorcovering 10 while the floor covering is positioned with the face surface22 facing upwardly. As one will appreciate, by applying theskid-resistant material 50 to the top surface of the cured embossedpolyurethane composition using a roll applicator 60, only the distalends 45 of the at least one male projection 44 will contact the rollapplicator. Therefore, as one will further appreciate, theskid-resistant material 50 can be applied to only the areas of the floorcovering 10 that will be in direct contact with a floor.

In still a further aspect, the step of curing the layer ofskid-resistant material 50 can be performed in a third pass through thetriple pass oven 110. However, as one will appreciate, because of theelevated temperature of the floor covering 10 at the time of applicationof the layer of skid-resistant material 50, a portion of the layer ofskid-resistant material can be cured before the third pass through theoven 110. Thus, during the third pass through the oven 110, any uncuredskid-resistant material 50 will be completely cured. During this thirdpass through the oven 110, the floor covering 10 can be positioned withthe face surface 22 facing downwardly. As one will appreciate,positioning the floor covering 10 with the face surface 22 facingdownwardly during the third pass through the oven 110 permits effectivecuring of the skid-resistant material 50.

In an additional aspect, the step of partially curing the foamablepolyurethane composition 36 can comprise substantially curing at leastabout 60% of the foamable polyurethane composition. In another aspect,the step of partially curing the foamable polyurethane composition 36can comprise substantially curing at least about 70% of the foamablepolyurethane composition. In a further aspect, the first pass throughthe oven 110, and thus, the partial curing of the foamable polyurethanecomposition 36, can be completed within about three to three and a halfminutes of applying the foamable polyurethane composition to the backsurface 24 of the greige good 20.

In exemplary embodiments, the foamable polyurethane composition 36 canhave a selected curing profile, wherein the polyurethane composition isexpected to be cured a given amount after a particular amount of timehas elapsed since the polyurethane composition is exposed to heat fromthe oven 110. In one specific exemplary embodiment, the foamablepolyurethane composition 36 can have a selected curing profile wherebythe polyurethane composition is cured about 10% at one minute afterexposure to heat, about 20% at two minutes after exposure to heat, about70% at three minutes after exposure to heat, about 75% at three and aquarter minutes after exposure to heat, about 90% at four minutes afterexposure to heat, and about 100% at five minutes after exposure to heat.

In a further aspect, during the step of curing the layer ofskid-resistant material 50, the skid-resistant material can be about 90%cured within about 10 seconds of applying the skid-resistant material tothe floor covering 10. As one will appreciate, the layer ofskid-resistant material 50 can be applied after the floor covering 10has been exposed to heat for about 6 to 7 minutes, thereby shorteningthe time required to substantially cure the skid-resistant material. Inan additional aspect, the skid-resistant material 50 can be about 100%cured by the end of the third pass through the oven 110. It iscontemplated that the third pass through the oven 110 can last for aboutthree to three and a half minutes.

In another aspect, the oven 110 can generate heat at a desired oventemperature to cure the floor covering 10. In one aspect, the desiredoven temperature can be between about 150° F. and 250° F., morepreferably between about 175° F. and 240° F., and most preferablybetween about 200° F. and 230° F. In an exemplary embodiment, the facesurface 22 of the floor covering 10 can be heated at an oven temperatureof about 220° F., while the back surface 24 of the floor covering can beheated at an oven temperature of about 200° F. In an additionalembodiment, the skid-resistant material 50 can be heated at an oventemperature of about 200° F. As one will appreciate, in a triple-passoven, each pass through the oven 110 can subject the floor covering 10to different temperatures. For example and without limitation, thedesired oven temperature can be 225° F. during the first pass throughthe oven, 200° F. during the second pass through the oven, and 200° F.during the third pass through the oven. As one will further appreciate,as the depth of the polyurethane composition increases, the oventemperature can be selectively increased to cure the polyurethanecomposition. For example, and without limitation, a polyurethanecomposition having a depth of approximately 3/16 inch can be heated atan oven temperature of about 200° F., while a polyurethane compositionhaving a depth of approximately 5/16 inch can be heated at an oventemperature of about 225° F.

As described herein, and referring to FIG. 1, FIG. 3A, and FIG. 3B, thefoamable polyurethane composition 36 can be thermo-embossed with thepre-determined pattern 40 to define at least one fluid pathway 42 incommunication with at least one side edge 15 of the floor covering 10.As one will appreciate, by partially curing the foamable polyurethanecomposition 36 prior to embossing, the foamable polyurethane compositionis soft enough to accept the embossing roller 100 and also stable enoughfor the structure of the at least one fluid pathway 42 to be maintainedduring the additional curing steps of the method.

The speed of the process can vary depending on the desired properties ofthe composite and/or manufacturing constraints. In preferredembodiments, the speed of the oven belt and/or the speed of the tenterapparatus is held at from about 5 feet per minute to about 60 feet perminute, or from about 10 feet per minute to about 50 feet per minute, orfrom about 15 feet per minute to about 40 feet per minute, or morepreferably 25 feet per minute to 45 feet per minute. In one specificembodiment, the speed of the oven belt can be held at about 35 feet perminute.

The present invention further provides a method for producing a floorbacking consistent with the method for producing the floor coveringdisclosed and described herein. In a first aspect, the method forproducing the floor backing comprises applying a foamable polyurethanecomposition as described herein to a back surface of a floor covering.In another aspect, the method comprises metering the appliedpolyurethane composition to form a substantially uniform layer of thefoamable polyurethane composition having a predetermined thickness. Inan additional aspect, the method comprises partially curing the foamablepolyurethane composition. In a further aspect, the method comprisesembossing the partially cured polyurethane composition with thepredetermined pattern. In still a further aspect, the method comprisescuring the embossed polyurethane composition.

In another aspect, the method can further comprise applying the layer ofskid-resistant material to at least a portion of the top surface of thecured embossed polyurethane composition. In an additional aspect, themethod can further comprise curing the layer of skid-resistant material.

The method for producing a floor backing as herein described is suitablefor use with virtually any floor covering application, including withoutlimitation, wood flooring, laminate flooring, sheet resilient flooring,residential carpeting, industrial carpeting, commercial carpeting,broadloom carpeting, carpet tiles, tufted carpets, needle-punchedcarpets, hand woven carpets, broadloom carpets, automotive carpets,carpet tiles, and even area rugs. Other suitable textiles includefabrics for automotive trim, and automotive trunk liners, syntheticplaying surfaces, woven polymeric scrim, non-woven polymeric scrim, wallcoverings, sheet polymers, furniture covers, and the like.

Experimental testing of the floor coverings and floor backings describedherein has demonstrated the ability of the floor coverings and floorbackings to disperse fluids away from the floor coverings and floorbackings. In one experiment, a fiberglass- and gel-coated boat deckingmaterial was cut into a 2 foot by 2 foot square and placed on a levelsurface. A 6 inch diameter of tap water, which amounted to approximately1 ounce of water, was poured onto the center portion of the uppersurface of the decking material. A 18 inch by 18 inch sample of a floorcovering as described herein was gently lowered onto the deckingmaterial with the water puddle in the center of the floor covering. Thefloor covering was not weighted and was positioned as a carpet mat wouldlie on a boat deck. The floor covering sample was removed at 24 hrs and48 hours for observation.

The experimental results demonstrated that the water was 80% dissipatedat 24 hours and 100% dissipated at 48 hours. As one will appreciate,these results indicate that the fluid pathways formed through thethermo-embossing of the backing layer of the floor covering as describedherein can promote evaporation and dispersal of fluids whilesimultaneously promoting flow of air into the fluid pathways.Importantly, both the cured polyurethane and skid-resistant material ofthe backing layer are waterproof and will not allow evaporation throughthe carpet. Therefore, as one will appreciate, fluids within the fluidpathways of the floor covering are guided to at least one side edge ofthe floor covering.

The preceding description of the invention is provided as an enablingteaching of the invention in its best, currently known embodiment. Tothis end, those skilled in the relevant art will recognize andappreciate that many changes can be made to the various aspects of theinvention described herein, while still obtaining the beneficial resultsof the present invention. It will also be apparent that some of thedesired benefits of the present invention can be obtained by selectingsome of the features of the present invention without utilizing otherfeatures. The corresponding structures, materials, acts, and equivalentsof all means or step plus function elements in the claims below areintended to include any structure, material, or acts for performing thefunctions in combination with other claimed elements as specificallyclaimed.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatan order be inferred, in any respect. This holds for any possiblenon-express basis for interpretation, including: matters of logic withrespect to arrangement of steps or operational flow; plain meaningderived from grammatical organization or punctuation; and the number ortype of embodiments described in the specification.

Accordingly, those who work in the art will recognize that manymodifications and adaptations to the present invention are possible andcan even be desirable in certain circumstances and are a part of thepresent invention. Other embodiments of the invention will be apparentto those skilled in the art from consideration of the specification andpractice of the invention disclosed herein. Thus, the precedingdescription is provided as illustrative of the principles of the presentinvention and not in limitation thereof. It is intended that thespecification and examples be considered as exemplary only, with a truescope and spirit of the invention being indicated by the followingclaims.

What is claimed is:
 1. A floor covering having a plurality of sideedges, comprising: a greige good having a face surface and a backsurface; and an embossed backing layer having a top surface and anopposed bottom surface, wherein the top surface of the backing layer isconnected to the back surface of the greige good, wherein the bottomsurface of the backing layer is thermo-embossed with a pre-determinedpattern, the predetermined pattern comprising a plurality of discretespaced male projections extending away from a plane positioned withinthe partially cured polyurethane composition and oriented substantiallyparallel to the back surface of the greige good, wherein each maleprojection has a top surface, wherein adjacent male projections of theplurality of discrete spaced male projections cooperate to define aplurality of fluid pathways, wherein each fluid pathway is incommunication with at least one side edge of the floor covering andconfigured to disperse fluid to the at least one side edge of the floorcovering; and wherein each top surface of the plurality of discretespaced male projections has a layer of skid-resistant material curedthereto, wherein the embossed backing layer is made by metering afoamable polyurethane composition to the back surface of the greige goodto form a substantially uniform layer of the foamable polyurethanecomposition having a predetermined thickness, partially curing thefoamable polyurethane composition, wherein the step of partially curingthe foamable polyurethane composition comprises substantially curing atleast about 60% of the foamable polyurethane composition, embossing thepartially cured polyurethane composition to define the predeterminedpattern, curing the embossed polyurethane composition, applying thelayer of skid-resistant material to only the top surface of theplurality of discrete spaced male projections of the cured embossedpolyurethane composition; and curing the layer of skid-resistantmaterial, wherein the steps of partially curing the foamablepolyurethane composition, curing the embossed polyurethane composition,and curing the layer of skid-resistant material are each separatelyperformed in a belted oven.
 2. The floor covering of claim 1, whereinthe plurality of discrete spaced male projections comprises a pluralityof raised serpentine bands.
 3. The floor covering of claim 2, whereinthe plurality of raised serpentine bands comprises a plurality ofsubstantially parallel raised serpentine bands.
 4. The floor covering ofclaim 1, wherein the oven is a triple-pass oven.
 5. The floor coveringof claim 1, wherein the step of partially curing the foamablepolyurethane composition is performed in a first pass through the oven,wherein the step of curing the embossed polyurethane composition isperformed in a second pass through the oven, and wherein the step ofcuring the layer of skid-resistant material is performed in a third passthrough the oven.
 6. The floor covering of claim 1, wherein thecross-sectional surface area of the distal ends of the plurality ofdiscrete spaced male projections is at least 20% of the cross-sectionalarea of the bottom surface of the backing layer.
 7. The floor coveringof claim 1, wherein the cross-sectional surface area of the distal endsof the plurality of discrete spaced male projections is at least 40% ofthe cross-sectional area of the bottom surface of the backing layer. 8.The floor covering of claim 1, wherein the cross-sectional surface areaof the distal ends of the plurality of discrete spaced male projectionsis at least 60% of the cross-sectional area of the bottom surface of thebacking layer.
 9. The floor covering of claim 1, wherein thecross-sectional surface area of the distal ends of the at least one maleprojection is at least 80% of the cross-sectional area of the bottomsurface of the backing layer.
 10. The floor covering of claim 1, whereinthe backing layer has a depth of between about 0.1 inch to 0.5 inch. 11.The floor covering of claim 10, wherein the backing layer has a weightbetween about 10 to about 50 ounces per square yard.
 12. The floorcovering of claim 10, wherein the backing layer has a weight betweenabout 20 to about 40 ounces per square yard.
 13. The floor covering ofclaim 10, wherein the backing layer has a density between about 8 toabout 22 pounds per cubic foot.
 14. The floor covering of claim 10,wherein the backing layer has a density between about 12 to about 14pounds per cubic foot.
 15. The floor covering of claim 10, wherein eachmale projection of the at least one male projection has a length ofbetween about 0.05 inch to 0.25 inch.
 16. The floor covering of claim 1,wherein the greige good comprises polypropylene.
 17. The floor coveringof claim 1, wherein the greige good comprises a non-woven primarybacking
 18. The floor covering of claim 1, wherein the greige goodcomprises a woven primary backing
 19. The floor covering of claim 1,wherein the skid-resistant material comprises an acrylic polymer. 20.The floor covering of claim 19, wherein the skid-resistant materialcomprises an acrylic polymer blended with water at a ratio of greaterthan 50% solids to water.
 21. The floor covering of claim 1, wherein atleast a portion of the greige good comprises reclaimed materials.
 22. Afloor covering having a plurality of side edges, comprising: a greigegood having a face surface and a back surface; and an embossed backinglayer having a top surface and an opposed bottom surface, wherein thetop surface of the backing layer is connected to the back surface of thegreige good, wherein the bottom surface of the backing layer isthermo-embossed with a pre-determined pattern, the predetermined patterncomprising a plurality of discrete spaced male projections extendingaway from a plane positioned within the partially cured polyurethanecomposition and oriented substantially parallel to the back surface ofthe greige good, wherein each male projection has a top surface, whereinadjacent male projections of the plurality of discrete spaced maleprojections cooperate to define a plurality of fluid pathways, whereineach fluid pathway is in communication with at least one side edge ofthe floor covering and configured to disperse fluid to the at least oneside edge of the floor covering; and wherein each top surface of theplurality of discrete spaced male projections has a layer ofskid-resistant material cured thereto, wherein the embossed backinglayer is made by metering a foamable polyurethane composition to theback surface of the greige good to form a substantially uniform layer ofthe foamable polyurethane composition having a predetermined thickness,partially curing the foamable polyurethane composition, wherein the stepof partially curing the foamable polyurethane composition comprisessubstantially curing at least about 60% of the foamable polyurethanecomposition, embossing the partially cured polyurethane composition todefine the predetermined pattern, curing the embossed polyurethanecomposition, applying the layer of skid-resistant material to only thetop surface of the plurality of discrete spaced male projections of thecured embossed polyurethane composition; and curing the layer ofskid-resistant material, wherein the step of partially curing thefoamable polyurethane composition is performed in a first pass throughan oven, wherein the step of curing the embossed polyurethanecomposition is performed in a second pass through the oven, and whereinthe step of curing the layer of skid-resistant material is performed ina third pass through the oven.
 23. The method of claim 22, wherein theplurality of discrete spaced male projections of the predeterminedpattern comprises a plurality of raised serpentine bands.
 24. The floorcovering of claim 22, wherein the cross-sectional surface area of thetop surfaces of the plurality of discrete spaced male projections is atleast 40% of the cross-sectional area of a bottom surface of the floorcovering.